DIY RC Plane Project Report.

TEAM MEMBERS:

    Satish Patil        – 3rdSem ECE
   
    Arpit Maurya        – 3rdSem EEE
     
    Souparna Baidya     – 3rdSem ECE
    
    Venkatesh Biradar   – 3rdSem CSE
      
      
     

Problem statement:

Design and build a low-cost, improvised (jugadu) RC fixed-wing aircraft primarily aimed at providing hands-on learning about the fundamental control surfaces and electronics of an airplane. The project will use easily available materials and avoid complex components such as flight controllers or onboard microcontrollers. Instead, the control system will rely solely on a basic RC transmitter–receiver pair, an ESC, a motor, a battery, and servos directly connected to the receiver.

The primary focus of this project is not on achieving optimal flight performance but on enabling practical understanding of:

• The working and effect of control surfaces (ailerons, rudder, elevator).
• Basic RC electronics integration without advanced stabilization systems.
• The challenges of balancing aerodynamics with simple DIY construction methods.

The outcome will be a functional RC plane that may fly efficiently and also demonstrates the core concepts of fixed-wing control in an affordable, experimental, and engaging way.

Target audience :

• Students and hobbyists who want to learn the basics of aerodynamics, RC electronics, and control surfaces.
• Beginners in aeromodelling who prefer a simple, low-cost, and hands-on project without diving into advanced flight controllers.
• DIY and maker community members who enjoy experimenting with jugadu solutions and repurposing materials for functional prototypes.
  Educators and trainers who wish to demonstrate the fundamentals of aircraft control in workshops or classrooms through a practical model.

Impact :

Educational Value: Provides a strong practical foundation in understanding how control surfaces influence flight, bridging the gap between textbook theory and hands-on experience.

• Skill Development: Encourages problem-solving, creativity, and resourcefulness by using improvised/jugadu methods to construct a working aircraft.
• Low-Cost Accessibility: Makes the concept of RC aerodynamics and electronics approachable for students and enthusiasts without requiring expensive equipment or advanced knowledge.
• Community Learning: Can be used in workshops, maker fairs, and student clubs as an engaging demo project to spark interest in aerospace, robotics, and electronics.
• Future Pathway: Serves as a stepping stone for learners to advance into more sophisticated RC models, flight controllers, UAVs, and aeronautical engineering concepts.

The work:

Overview and scope:

The project is a DIY fixed-wing RC aircraft built with low-cost, easily available materials and a simple electronics setup. Unlike conventional RC planes that rely on microcontrollers or advanced flight controllers, this plane uses a direct connection system where servos are controlled straight from the receiver. The aim is to understand the fundamentals of aerodynamics, control surfaces, and RC electronics through a practical, hands-on approach, while keeping the design minimal and budget-friendly.

It's designed for learning, experimentation, and innovation using "jugaad" (creative improvisation).

Technical features :

1. Airframe Modification

Base model: $2 foam glider adapted into RC airplane.
Lightweight plastic reinforcements added for durability without adding excess weight.
Cockpit, wings, and tail reshaped to house electronics and improve control authority.

2. Motor & Propulsion System

o Flexible motor mounting system $\rightarrow$ absorbs impact in crashes, protecting motor/prop.
Efficient motor-propeller setup enabling higher thrust-to-weight ratio.

Improved speed and agility compared to stock glider.

3. Control Surfaces & Servos

Custom servo placement for precise control of elevator, rudder, and dual-wing control.
Optimized to run with limited servos, keeping build light and cost-effective.
Enhanced maneuverability with aerobic capability.

4. Electronics Integration

o Compact integration of receiver, ESC, servos, and LiPo battery inside modified cockpit.
o Extended battery life due to efficient electronics layout and lightweight build.
o Balanced center of gravity (CG) achieved via careful component positioning.

5. Engineering Solutions

o Flexible motor suspension prevents permanent damage during crashes.
○ Reinforced control linkages to withstand stress during aerobatics.
o Smart use of low-cost, DIY-friendly materials for high performance.

How our project is different from competitors?

Simplicity over Complexity

• Most RC planes (competitors) rely on flight controllers, stabilization systems, or autopilot features.
• Our project intentionally removes all advanced electronics $\rightarrow$ it's direct Tx-Rx-Servo control, making it a pure learning experience.

Low-Cost & Jugaad-Friendly

Competitor RC planes (kits or commercial models) are expensive and use specialized materials.

• Our project uses readily available, low-cost, and locally sourced materials, making it more accessible to students and hobbyists.

Educational Orientation

Instead of focusing only on "flying performance," this project emphasizes understanding the basics of aerodynamics and electronics.

• Competitors often skip fundamentals because their models are plug-and-play or too advanced.

Hands-On Experimentation

• Other RC planes come pre-designed and optimized; users just fly them.
• Here, the builder has to design, balance, and tune $\rightarrow$ giving deeper engineering insights into center of gravity, thrust-to-weight ratio, and wing loading.

Modular & Expandable

• While it starts minimal, it has a clear upgrade path: we can add flight controllers, sensors, or even turn it into a UAV later.
• Competitors often lock into fixed designs without room for learning-based modifications.

Pre-requisites / Assumptions / Datasets:

Pre-requisites

Skills / Knowledge

Basic soldering and wiring.

• Fundamental aerodynamics: lift, drag, weight, thrust, stall.
• Understanding of RC basics: transmitter (Tx), receiver (Rx) channels, servo reversing/travel, ESC, LiPo charging/safety.
• Basic mechanical skills: cutting, gluing (foam/ply/Depron), balancing (CG).
• Basic troubleshooting: servo throws, radio failsafes, motor/ESC calibration.
• Basic safety practices for LiPo batteries and propellers.

Assumptions :

Non-commercial, educational use only.

Line-of-sight visual operation during test flights.

Open flying area with no people/crowds nearby (e.g., sports field).

Local aviation rules will be followed.

Ambient weather for flights: light wind (<10-15 km/h) and no rain.

Flights are low-altitude and gentle — trimming before aggressive maneuvers.

Design

Outcome:

1. Functional Prototype

○ A working RC fixed-wing aircraft capable of manual remote-controlled flight (take-off, cruising, maneuvering, and landing).
o Demonstrates direct Tx-Rx-Servo control without any flight controller.

2. Educational Outcome

o Practical understanding of aerodynamic principles (lift, thrust, drag, stability).
○ Hands-on learning of RC electronics integration (motor + ESC + servos + LiPo + receiver).
Insight into airframe balancing, weight distribution, and CG adjustments.

3. Skill Development

Improved mechanical and electrical assembly skills.
$\circ$ Exposure to troubleshooting techniques in RC systems (servo response, motor calibration, CG tuning).
o Basics of data collection & analysis (flight logs, thrust tests, battery usage).

4. Innovation & Creativity

• Showcases how low-cost, locally sourced, "jugaadu" materials can still produce a functional RC aircraft.
  o Encourages experimentation with wing designs, fuselage builds, and power systems.
  Opens the pathway for future modifications (autopilot, GPS, sensors, FPV).

5. Community & Academic Impact

o Suitable as a teaching model for schools, colleges, and hobby clubs.
o Can be used as an entry-level aeromodelling project in competitions.

• Acts as a foundation project before advancing into drones, UAVs, or autonomous aircraft.

Limitations

1. Mechanical wear and durability

Gears (especially plastic ones) may wear out or break under repeated/misaligned loads.

1. Mounting and Space constraints

Physical space might limit servo size. If a larger servo is needed (for high torque), fitting it might be problematic.

1. Cost & Component Availability

High-torque, metal gear servos are more expensive. Replacements may be hard to get locally.

Timeline

This project will take approximately 4 months to make. We will work on it during weekends and whenever free during weekdays.

Tools / Equipments

S.No	Components Required	Price	Quantity	Total
1	Aeroplane Body	₹249	1	₹249
2	Motor (for Propeller)	—	1	—
3	Soldering Iron	—	—	—
4	Wooden Stick	—	—	—
5	Tape	—	—	—
6	Servo Motor	NA	2	NA
7	Slit	NA	3	NA
8	Standard Wire	—	—	—
9	Control Board	₹1099	1	₹1099
10	6 A, 32-bit ESC	—	1	—
11	Li-Po Battery	₹352	1	₹352
12	Small Magnets (spherical)	—	2	—
13	Pair of Screws	—	—	—
14	Propeller	₹109	1	₹109
15	Switch	₹119	1	₹119
16	Remote Controller	—	1	—

| Total Cost | | | | ₹1928 |.